Method and Apparatus For Placement of ADAS Fixtures During Vehicle Inspection and Service

ABSTRACT

A system and method for guiding placement of a vehicle service external fixture relative to a vehicle undergoing service or inspection. A vehicle service system support structure having at least one camera module is positioned at an initial location within a vehicle service area, and a location of the initial location within a vehicle reference frame is established from images of optical targets secured to the vehicle. The vehicle service system support structure is subsequently repositioned relative to the vehicle to a new position located outside of an external fixture placement region, while maintaining at least one of the observed optical targets within a field of view of the camera module. The new position of the vehicle service system support structure within said vehicle reference frame is determined from target images, and a placement location within the placement region for the external fixture is identified relative to the vehicle.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of, and claims priority from,co-pending U.S. patent application Ser. No. 17/147,896 filed on Jan. 13,2021, which in turn is a divisional of U.S. patent application Ser. No.16/538,245 filed on Aug. 12, 2019, now U.S. Pat. No. 11,145,084 B2,which in turn claimed priority to U.S. Provisional Patent ApplicationSer. No. 62/725,023 filed on Aug. 30, 2018. Each of the aforementionedapplications and patent are herein incorporated by reference.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH

Not Applicable.

BACKGROUND OF THE INVENTION

The present application is related to a fixture for facilitating thecalibration and alignment of vehicle safety system sensors, and inparticular, to a movable fixture supporting vehicle wheel alignmentsystem imaging sensors and for facilitating proper placement of at leastone calibration or alignment target associated with a vehicle safetysystem sensor in operative proximity to a vehicle undergoing a serviceor inspection.

Vehicle wheel measurement systems, such as wheel alignment or inspectionsystems employing machine vision technology, such as cameras observingoptical targets mounted on various surfaces within associated fields ofview are well known in the vehicle measurement, alignment, andinspection industry. Typically, these types of systems employ multiplecameras, mounted to a crossbeam member on a fixture or structure locatedin front of a vehicle service area. The cameras are oriented such thateach wheel of a vehicle to be inspected (or target mounted thereon)within the service area is visible to at least one of the cameras. Thestructure supporting the camera crossbeam may be fixed in place, or maybe mobile, configured to be moved from one service area to another asneeded. The camera crossbeam itself may be vertically (and/orrotationally) adjustable to accommodate vehicles at different elevationsof a lift rack within the vehicle service. Images acquired by thecameras are conveyed to a wheel alignment processing system configuredwith suitable software instructions for image evaluation, determiningvarious spatial measurements associated with the observed surfaces, andultimately for identifying vehicle wheel alignment angles fromassociated spatial measurements.

When it is necessary to realign or recalibrate various vehicle safetysystem sensors, such as radar units or optical sensors typicallyutilized in forward collision avoidance systems or adaptive cruisecontrol systems, specialized structures are precisely positioned inproximity to the vehicle, often with the aid of a vehicle measurementsystem such as a wheel alignment or inspection system. For example, U.S.Pat. No. 7,382,913 B2 to Dorrance describes a method and apparatus forguiding placement of a vehicle service apparatus relative to a vehicle,based on measurements acquired by a separate vehicle wheel alignmentmeasurement system. Other techniques for guiding placement of aspecialized structure relative to a vehicle undergoing a realignment orrecalibration of a vehicle safety system sensor include the use of laseremitters and leveling devices, such as shown in U.S. Pat. No. 6,583,868B2 to Hopfenmuller.

Positionable fixtures or support structures capable of supporting boththe cameras associated with a vehicle measurement system as well asspecialized structures required for realignment or recalibration ofonboard vehicle safety system sensor, such as shown in PublishedInternational Patent Application No. WO 2018/067354 A1 to HunterEngineering Company have been developed, thereby reducing the totalnumber of fixtures required to complete a vehicle onboard sensorrealignment or recalibration, and eliminating potential spatialconflicts between support structures and specialized structures.

However, some specialized structures or optical targets used in thealignment or calibration of onboard vehicle safety system sensors cannotbe secured to the positionable fixture or support structure.Accordingly, there is a need to provide a system to guide an operator inthe proper placement of those specialized support structures or opticaltargets relative to either the vehicle undergoing service or to thepositionable fixture or support structure itself. In some cases, theoperator may require guidance as to the proper placement of thepositionable fixture or support structure itself.

BRIEF SUMMARY OF THE INVENTION

Briefly stated, the present disclosure sets forth a fixture or supportstructure having a vertical element supporting a set of camerasassociated with a vehicle measurement system, together with at least onegimbaled guidance system disposed to project visible indicia ontosurfaces in proximity to the fixture or support structure for guidingrelative placement of vehicle service components. A camera crossbeamcarried by the fixture or support structure locates the set of camerasin a laterally spaced arrangement, as required to view wheels on eachside of a vehicle undergoing measurement, wheel alignment, orinspection, and is optionally vertically (and/or rotationally)adjustable to accommodate the vehicle disposed at different elevationson an adjustable lift rack. The gimbaled guidance system is carried bythe camera crossbeam structure, and is operatively coupled to aprocessing system configured with software instructions to selectivelycontrol an orientation of the gimbaled guidance system about one or moreaxis of rotation, enabling projection of visible indicia onto surfacesat selected locations relative to the vehicle or the support structure.

In a further embodiment, the present disclosure sets forth a fixture orsupport structure having a vertical element supporting a set of camerasassociated with a vehicle measurement system, together with at least onegimbaled measurement system disposed to acquire data associated withsurfaces in proximity to the fixture or support structure for guidingrelative placement of vehicle service components. A camera crossbeamcarried by the fixture or support structure locates the set of camerasin a laterally spaced arrangement, as required to view wheels on eachside of a vehicle undergoing measurement, wheel alignment, orinspection, and is optionally vertically (and/or rotationally)adjustable to accommodate the vehicle disposed at different elevationson an adjustable lift rack. The gimbaled measurement system is carriedby the camera crossbeam structure, and is operatively coupled to aprocessing system configured with software instructions to selectivelycontrol an orientation of the gimbaled measurement system about one ormore axis of rotation, enabling acquisition of images from either acamera having a field of view oriented parallel to one of the axis ofrotation, or distance measurements along a measurement axis aligned withone of the axis of rotation to surfaces at selected locations relativeto the vehicle or the support structure.

In a method of the present disclosure, proper placement of vehicleservice fixtures relative to a vehicle undergoing service or inspectioncan be verified by: (1) establishing a location of the vehicle within avehicle reference frame; (2) identifying a placement location for thevehicle service fixture relative to the vehicle within the vehicle frameof reference; (3) directing an operator to position the vehicle servicefixture at the identified placement location; (4) orienting a field ofview of a movable camera to acquire an image of the identified placementlocation, where the camera has a known position and orientation withinthe vehicle frame of reference; and (5) evaluating the acquired image toidentify a presence or an absence of the vehicle service fixture.

In an alternative method, proper placement of vehicle service fixturesrelative to a vehicle undergoing service or inspection can be verifiedafter placement of the fixture by an operator by: (1) orienting ameasurement axis of a movable range sensor towards an expected locationof a surface on the vehicle service fixture, wherein the movable rangesensor disposed at a known position within a vehicle frame of reference;(2) acquiring a distance measurement to a surface on the measurementaxis; (3) evaluating the acquired distance measurement to identify apresence or an absence of the vehicle service fixture at the identifiedplacement location; and (4) responsive to an identified presence of thevehicle service fixture, comparing the acquired distance measurementwith an expected distance measurement based on a known position of themovable sensor and the identified placement location, to determine ifthe vehicle service fixture is properly positioned at the identifiedlocation to within an acceptable tolerance.

In a further method, the present disclosure sets forth a procedure tofacilitate a proper placement of vehicle service fixtures withoutinterference with a machine-vision vehicle inspection system normallypositioned in front of the vehicle. With the vehicle positioned in aservice area, and the vehicle inspection system initially disposed infront of the vehicle, the vehicle inspection system is operated toacquire a set of vehicle measurements from at least one wheel assemblyon each lateral side of said vehicle, and to establish a vehicle frameof reference and/or a vehicle reference line from the acquired set ofvehicle measurements. A first location of the vehicle inspection systemrelative to a visible reference point within the vehicle frame ofreference having a determinable relationship with the vehicle isidentified. To provide an unobstructed line of sight between the vehicleand a vehicle service fixture placement location within the vehicleservice area in front of the vehicle, the vehicle inspection system isrepositioned to a second location while maintaining the visiblereference point within a field of view of at least one camera module,enabling the vehicle inspection system to identify the new locationwithin said vehicle frame of reference relative to the visible referencepoint. Once repositioned, the vehicle inspection system is operated toprovide a visual identification of the placement location for thevehicle service fixture within the vehicle frame of reference utilizingthe identified second location and the vehicle reference line.

The foregoing features, and advantages set forth in the presentdisclosure as well as presently preferred embodiments will become moreapparent from the reading of the following description in connectionwith the accompanying drawings.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

In the accompanying drawings which form part of the specification:

FIG. 1 is a perspective view of a prior art camera and a target supportstructure coupled to a control console;

FIG. 2 is a top plan view of the prior art support structure of FIG. 1disposed in proximity to a vehicle undergoing a measurement, inspection,or wheel alignment service;

FIG. 3 is a side view of the prior art support structure of FIG. 1;

FIG. 4 is a perspective view of an embodiment of the present disclosure,illustrating a support structure configured with a pair ofgimbal-mounted projection systems;

FIG. 5 is a close-up perspective view of a gimbal-mounted projectionsystem of

FIG. 4 mounted to the support structure;

FIG. 6 is a front perspective view of an alternate gimbal-mountedprojection and measurement system;

FIG. 7 is a rear perspective view of the gimbal-mounted projection andmeasurement system of FIG. 6;

FIG. 8 is a top plan view illustrating visible indicia projected withoptical projectors coupled to the gimbal-mounted guidance system of FIG.5; and

FIG. 9 is a top plan view illustrating a repositioning of the targetsupport structure during a vehicle measurement, inspection, or wheelalignment service.

Corresponding reference numerals indicate corresponding parts throughoutthe several figures of the drawings. It is to be understood that thedrawings are for illustrating the concepts set forth in the presentdisclosure and are not to scale.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the drawings.

DETAILED DESCRIPTION

The following detailed description illustrates the invention by way ofexample and not by way of limitation. The description enables oneskilled in the art to make and use the present disclosure, and describesseveral embodiments, adaptations, variations, alternatives, and uses ofthe present disclosure, including what is presently believed to be thebest mode of carrying out the present disclosure.

While the present disclosure sets for various embodiments in whichcameras, laser emitters, range finders, etc., are disposed on a movablefixture or support structure for observing, illuminating, and measuringsurfaces and/or other fixtures in proximity to the movable fixture orsupport structure, it will be understood by one of ordinary skill in theart that the relationships may be reversed without departing from thescope of the inventions, such that the cameras, laser emitters, rangefinders, etc., are disposed on the other fixtures and utilized toobserve, illuminate, or measure distances to the movable fixture orsupport structure.

Turning to the figures, and to FIGS. 1-3 in particular, a vehiclemeasurement system instrumentation fixture or support structure 100 isshown, having a vertical column 102 supporting a set of laterally spacedcamera modules 104 a, 104 b associated with a vehicle measurementsystem, such as a vehicle wheel alignment or inspection system. At leastone vehicle calibration assistance structure, consisting of aspecialized target structure 400 a, 400 b is coupled to the supportstructure 100 and utilized to facilitate a process for realigning orrecalibrating one or more safety system sensors onboard a vehicle 10undergoing a service procedure in proximity to the support structure100.

A camera crossbeam 106 carried by the vertical column 102 on the supportstructure 100 locates the set of camera modules 104 a, 104 b adjacentopposite longitudinal ends. Each camera module contains one or morefixed cameras 105 with fields of view oriented in a generally forwarddirection to observe each lateral side of the vehicle 10 undergoingservice. The camera crossbeam 106 is optionally vertically (and/orrotationally about its longitudinal axis) adjustable relative to thevertical column 102 to accommodate elevation changes in the vehicle 10if it is located on an adjustable lift rack (not shown), or toaccommodate changes in the placement of the support structure 100relative to the vehicle 10. Vertical and/or rotational adjustments tothe camera crossbeam 106 may be manual or automatic, by any conventionalmeans, such as sliding rails, rod and screw mechanisms, pulleymechanism, etc. As an alternative to rotationally adjusting the cameracrossbeam 106, individual camera modules 104 a, 104 b may be configuredwith suitable coupling mechanisms to permit multi-axis independentmovement as required to achieve desired fields of view with the cameras105, and to facilitate positioning targets in proper locations.

It will be recognized that while the embodiments of the vehiclemeasurement system instrumentation structure illustrated in the Figuresand described above utilize a vertical column 102 and a camera crossbeam106, other configurations of a camera support structure 100 may beutilized without departing from the scope of the present invention. Forexample, in place of the vertical column 102 and camera crossbeam 106, acamera support structure 100 may consist of articulated camera supportarms adapted to position individual cameras in laterally spacedarrangements as required to achieve the fields of view necessary toobserve features or targets associated with a vehicle undergoing a wheelalignment service, measurement, or inspection.

The camera modules 104 a, 104 b are operatively coupled to a processingsystem 300, which may be disposed in an associated console 302 inproximity to the fixture or support structure 100. The processing system300 is configured with suitable logic circuit components and withsoftware instructions for receiving image data from the camera modules104 a, 104 b, evaluating the image data from at least one of the cameramodule to identify relative spatial positions of observed surfaces, suchas optical targets disposed on the wheels 12 or surfaces of a vehicle10, for performing spatial transformations between various individualframes of reference, and for computing associated vehiclecharacteristics, such as wheel alignment angles or vehicle bodyposition. It will be understood that the configuration of the processingsystem 300, camera modules 104 a, 104 b, and console 302 are generallyknown in the art of machine vision vehicle wheel alignment systems, andmay vary from the specific configuration described herein withoutdeparting from the scope of the invention, so long as the processingsystem 300 is capable of determining at least the relative spatialposition of one or more observed surfaces associated with the vehicle10.

To facilitate alignment and calibration of safety system sensors onboarda vehicle 10, such as radar, LIDAR or optical sensors, one embodiment ofthe vehicle calibration assistance structure 100 includes at least onetarget structure 400 a and/or 400 b affixed to the camera supportstructure 100, such as to the vertical column 102 or camera crossbeam106, by a multi-axis mounting fixture 402. Each target structure 400 a,400 b includes an observable target face oriented in a generally forwarddirection from the fixture or support structure 100 (i.e., towards thevehicle service area), at an elevation generally suitable forobservation by the safety system sensors onboard the vehicle 10 during arealignment or recalibration procedure. The specific configuration ofthe target structures 400 a, 400 b, such as the target face features, isrelated to, and will vary with, the specific type of safety systemsensor for which it will be used. For example, an optical target 400 ahaving retro-reflective or contrasting target face surface features maybe provided for use with optical safety system sensors such as camerasor LIDAR. Correspondingly, a metallic or radar-reflective target 400 bmay be provided for use with radar-based safety system sensors. As seenin the various figures, multiple individual target structures of eitherthe same or different types, may be secured to the vertical column 102at different vertical elevations or horizontal separations.

The mounting fixture 402 may be a fixed mount which secures the targetstructures 400 a, 400 b in a fixed position and orientation relative tothe vertical column 102, or optionally, may include suitable multi-axismechanisms for adjusting the lateral position, vertical position, and/ororientation of the target structures 400 a, 400 b over a limited rangerelative to the vertical column 102, such as may be required for safetysystem sensors offset from a vehicle centerline CL or thrust line TLafter the fixture or support structure 100 is disposed generally infront of the vehicle, as seen in FIG. 2. For example, a lateral supporttrack 404 shown in FIGS. 1-4 may be coupled to the mounting fixture 402,parallel to the camera crossbeam 106 to support a target structure forsliding movement, enabling a lateral position of a target structure 400a to be adjusted.

In one embodiment, to facilitate positioning of the fixture or supportstructure 100 generally at the vehicle centerline CL (or thrust line)and to enable the set of camera modules 104 a, 104 b to view features oneach lateral side of the vehicle 10, the fixture or support structure100 is provided with a base structure 108 having a set of rollingelements, such as casters or wheels 109. Exemplary wheels may includeomni-directional wheels such as Omni wheels or Mecanum wheels havingsmall discs around their circumference. Optionally, the wheels may becoupled to a drive motor for powered movement of the support structure100. During use, the fixture or support structure 100 is positionedmanually by an operator, under operator control through the processingsystem 300, or automatically by the processing system 300, at a selecteddistance from the front of the lift rack or support surface on which thevehicle 10 is disposed during the measurement, inspection, or wheelalignment service procedure. Different vehicles may require the fixtureor support structure 100 to be positioned at different locationsrelative to the vehicle. An optional locking mechanism may be providedon at least one of the rolling elements, to prevent accidental movementof the fixture or support structure 100 during use.

Precise position of the fixture or support structure 100 to place thetarget structure 400 in an ideal location for use may be carried outautomatically or by the operator under the guidance of the processingsystem 300 in response to data acquired through the processing of imagesacquired by the camera modules 104 a, 104 b. For example, with thefixture or support structure 100 positioned generally on the centerlineCL of a vehicle 10 as seen in FIG. 2, (or alternatively to a determinedthrust line of the vehicle) the camera modules 104 a, 104 b can acquireimages associated with the front and rear wheels 12 on each lateral sideof the vehicle, from which the processing system 300 identifies theposition of the fixture or support structure relative to either ageometric centerline CL or a thrust line TL of the vehicle 10. Ifadjustments to the position of the fixture or support structure 100relative to either the vehicle's geometric centerline CL or thrust lineTL are required, suitable, signals directing movement are provided tothe drive motors or operator by the processing system 300 based on thedetermined relative position of the fixture or support structure.

Positioning of the fixture or support structure 100, if adjustable, maybe relative to a single axis which is generally transverse to thevehicle centerline CL (i.e., from side to side), or may be relative toan additional axis which is generally parallel to the vehicle centerlineCL (i.e., towards or away from the vehicle). A vertical height of theset of the camera modules 104 a, 104 b is optionally adjusted by raisingor lowering the camera crossbeam 106 along the vertical column 102.

Once the fixture or support structure is positioned at a desiredlocation relative to the vehicle 10, adjustments to the position andorientation of the target structure 400 a, 400 b relative to thevertical column 102 for proper placement within a field of viewassociated with the onboard vehicle safety system sensors can be donevia the mounting fixture 402. Suitable adjustment mechanisms within themounting fixture 402 may include, but are not limited to, ball andsocket connections, pivot arms, and the sliding rail or track 404. Withthe target structure 400 a, 400 b positioned at the desired locationrelative to the vehicle, and more specifically, relative to an onboardvehicle sensor, measurement, alignment, or calibration of the onboardvehicle sensor can proceed as understood in the art, by observing orilluminating the target structure 400 and responding accordingly.

The vehicle calibration assistance structure includes one or moreoptical projectors 500 operatively coupled to, and under control of, theprocessing system 300, for the projection of visible indicia 501 on tosurfaces in proximity to the fixture or support structure, utilized toaid in the placement or alignment of vehicle service fixtures ortargets. Exemplary surfaces onto which visible indicia may be projectedinclude the vehicle body, wheel-mounted targets, targets or locations onthe service bay floor surfaces, and movable targets located within theservice bay. Each optical projector 500 as illustrated in FIGS. 5-7comprises a pair of laser modules 500 a and 500 b. Each laser module ismounted on a set 502 of motorized multi-axis gimbals secured to thecamera cross beam 106. The laser modules 500 a, 500 b are disposed in alaterally spaced arrangement on the camera cross beam 106, in proximityto the camera modules 104 a and 104 b, enabling projection of visibleindicia onto surfaces located within the vehicle service area, such asadjacent each lateral side of the vehicle 10 as shown in FIG. 6. Eachlaser module 500 a, 500 b, as seen in FIG. 5, includes at least onelaser line emitter 504 secured to the set 502 of gimbal motors 503 a,503 b, and 503 c for controlled rotational movement about at least twoorthogonal axes (X, Y, and/or Z).

Optionally, as shown in FIGS. 6 and 7, second laser emitter 506 issupported by an outboard gimbal motor 508 on the mounting structure 502,for rotation about a fourth additional axis R, parallel to one of theorthogonal axes (X, Y, and/or Z), enabling projected indicia or laserlines to be rotated about the projection axis. Rotating one of theprojected indicia or laser lines enables the processing system 300 tovisually correct for parallax distortion resulting from non-orthogonalprojection orientations. The laser emitters 504 and 506 each projectbeams 507 of visible light through associated optical focusing elementsto illuminate visible indicia in the form of spots or lines, on thesurfaces. It will be recognized that the optical projectors 500 mayutilized other sources of visible light, such as LED elements, andassociated optical focusing elements in place of the laser emitters 504,506 to project indicia visible to an operator and/or to an observingcamera system, such as spots or points, or illumination of differentcolors, onto the surfaces without departing from the scope of thepresent disclosure. Furthermore, the specific number of axes about whichthe optical projectors 500 are configured for movement may vary based onthe intended use of the projected indicia. For example, opticalprojectors 500 intended to project indicia at a fixed location relativeto the fixture or support structure 100 may be mounted in a fixedorientation, while optical projectors such as 500 a and 500 b which areintended to project indicia onto surfaces at varying locations relativeto either the vehicle, fixture, or reference within the service bay, aremounted for rotational movement about multiple axes.

During a vehicle wheel alignment service, measurement, or inspectionprocedure, the processing system 300 is configured to control the set502 of multi-axis gimbal mounting structures, and optional outboardgimbal motor 508, to orient each laser emitter 504, 506 to project theobservable indicia 501 at a selected location on a surface in proximityto the fixture or support structure 100. The observable indicia 501 isconfigured to represent a stationary point location to aid in theplacement of a vehicle service fixture 600, or to represent lines orboundaries against which an elongated planar optical target 602 or othervehicle service device may be aligned. The processing system 300optionally controls the set of multi-axis gimbal mounting structures toimpart motion to the projected indicia, such as to sequentiallyilluminate two or more discrete locations on said surface. Indicia otherthan points or lines, such as alphanumeric symbols, or raster images, orvisible indicia of different colors, may be projected under control ofthe processing system 300 from suitably configured optical projectors500 within the scope of the present disclosure.

In one embodiment, the selected location of the observable indicia 501on the surface is determined by the processing system 300 in response tospatial measurements of associated with the vehicle 10 acquired fromimages captured by the camera modules 104, or is selected to be relativeto a component of the fixture or support structure 100, such as an axisof the support column 102. For example, some vehicle safety systemsensor calibration procedures require the placement of targetstructures, observable by onboard vehicle safety system sensors, atselect locations relative to the vehicle. Specific placementrequirements associated with safety system calibration procedures for avariety of vehicle makes and models may be stored in a databaseaccessible to the processing system 300. After determining measurementsassociated with the relative spatial position of the vehicle 10 to thefixture or support structure 100, such as by conventional machine visionvehicle alignment measurement procedures, the processing system 300 isconfigured with software instructions to access the database to recallthe placement requirements for visible targets or calibrations fixtures600 associated with the vehicle. Utilizing the recalled placementrequirements, the processing system 300 operates the set 502 ofmotorized gimbal mounting structures to directly orient the opticalprojectors to project visible indicia at the appropriate locations onthe floor surface of the vehicle service area, enabling an operator toplace targets or structures necessary to carry out or complete a vehicleservice, calibration, or inspection procedure.

In a further embodiment, the processing system 300 utilizes images fromthe camera modules 104 a, 104 b to observe a location of the projectedvisible indicia relative to the vehicle, a wheel mounted target, orother reference location visible within images captured by the cameramodules. The processing system 300 is configured with softwareinstructions to utilize the observed location to operate the set 502 ofmotorized gimbal mounting structures to alter an orientation of theoptical projectors to adjust the location of the projected indicia fromthe observed location to a location required for the operator to carryout or complete a vehicle service calibration or inspection procedure.

In addition to operating the set of motorized gimbal mounting structuresto orient the optical projectors to project the visible indicia at theselected locations on the floor surface, the processing system 300 maybe further configured to provide for motion stabilization of theprojected visible indicia in response to movement of the fixture orsupport structure 100. Motion stabilization, via control of the set ofmotorized gimbal mounting structures, may be provided by the processingsystem 300 to maintain the projected visible indicia at the selectedlocation during movement of the base 108 across the floor surface, aswell as during vertical movement of the camera crossbeam 106.

In another embodiment, the fixture or support structure 100 isconfigured with at least one secondary optical camera system 700 mountedto a motorized multi-axis gimbal. The optical camera system has a fieldof view suitable for viewing targets disposed in proximity to thevehicle 10 and/or within the vehicle service area. The motorizedmulti-axis gimbal incorporates rotational position encoders associatedwith each rotational axis, such that a spatial orientation of thesecondary optical camera system field of view can be identified,tracked, and controlled by the processing system 300.

Turning to FIGS. 6 and 7, the secondary optical camera system 700 may besupported directly on the motorized gimbal mounting structure 502 of oneof the laser modules 500 a or 500 b, aligned with a field of viewparallel to an axis of one of the associated laser emitters 504 and 506,eliminating the need for a separate motorized multi-axis gimbaldedicated to the camera system 700. With suitable software programminginstructions, the processing system 300 utilizes the secondary opticalcamera system to observe targets 602 within a field of view associatedwith the current orientation of the laser module 500 a, 500 b onto whichthe camera system 700 is mounted. Proper placement of a target relativeto the secondary optical camera system 700 or other established frame ofreference, such as the vehicle (based on observations of wheel adaptertargets) can be determined by the processing system 300 by analyzing anobserved location of the target within the camera system field of view,together with gimbal encoder data identifying a multi-axis spatialorientation of the field of view (i.e. reference frame). If necessary,the processing system 300 can drive the motorized gimbal mountingstructure 502 to orient the secondary optical camera system 700 field ofview as required to observe an area in proximity to a vehicle or servicebay in which a target 602 is expected to be placed. If the target is notobserved within the field of view following the orientation of thesecondary optical camera system 700, a warning or other suitableindication to an operator may be provided.

The processing system 300 may be configured with software instruction toutilize the secondary optical camera system 700 to determine if anexternal fixture 600 or target 602 has been properly positioned relativeto a location indicated by optical projector 500 on the fixture orsupport structure 100. Once the optical projector 500 is oriented toilluminate a specific point or location for placement of the externalfixture 600 or target 602, an operator moves or places the externalfixture 600 or target 602 at the indicated location. Preferably, theexternal fixture 600 or target 602 includes a point or referencemarking, such as a crosshair or bulls-eye icon, which is to be alignedwith an illuminating laser from the optical projector 500. For theprocessing system 300 to determine if a point of illumination from alaser module 500 a, 500 b is aligned with an observable referencelocation on the external fixture 600 or target 602, one or more imagesare acquired by the secondary optical camera system 700 oriented to viewthe indicated location.

Alternatively, the external fixture 600 or target 602 may be configuredwith an optical receptor responsive to incident illumination. Theoptical receptor may be integrated into the external fixture 600 ortarget 602, or may consist of a self-contained module suitable forplacement on the fixture, target or other surface. In one configuration,the optical receptor is responsive to laser illumination to activate avisual indicator, such as an LED once the external fixture 600 or target602 is properly positioned with respect to any incident laserillumination from the optical projector 500, enabling an operator tovisually confirm proper placement.

Configured with software instructions, the processing system 300 cananalyze images of the external fixture 600 or target 602 acquired by thesecondary optical camera system 700, and confirm activation of, or apresence of, the visual indicator to verify proper positioning of theexternal fixture 600 or target 602. Alternatively, the optical receptoris configured to respond to incident illumination by emitting a wirelesssignal or other form of suitable feedback detectable by the processingsystem 300.

In addition to confirming proper positioning of an external fixture 600or target 602, a feedback system responsive to incident illumination maybe utilized to facilitate position calibration of the laser modules 500a, 500 b by enabling the processing system 300 to confirm that the lasermodules are accurately responding to commands for orientating theilluminating lasers about each rotational axis of the motorized gimbalmounting structure 502. The processing system 300 is configured withsoftware instructions to drive the individual gimbal motors supportingeach laser module in order to align the illuminating lasers withspecific calibration targets in three dimensional space. The calibrationtargets may optionally be located on the fixture or support structure100 itself, enabling a self-calibration procedure. Failure to receiveappropriate responsive feedback at the processing system 300, such asfrom an operator, from a visual indicator, or an emitted signalresponsive to incident illumination, is an indication to the processingsystem 300 that the illuminating lasers are not oriented to properlyilluminate the specific calibration point or reference marking. Asuitable warning to an operator can be provided by the processing system300, indicating the need for a corrective action or recalibration.

In a further embodiment, a non-contact distance measurement sensor 800is secured to the motorized gimbal 502. The distance measurement sensor800 may be any of a variety of suitable sensors, such as a laser rangefinder, a radar system, or a Lidar system, having an operating rangesuitable for determining distances to targets disposed in proximity tothe vehicle 10 and/or within the vehicle service area. The motorizedgimbal 502 incorporates rotational position encoders associated witheach rotational axis, such that a spatial orientation of a measurementaxis associated with the distance measurement sensor 800 can beidentified, tracked, and controlled by the processing system 300.Optionally, as seen in FIGS. 6 and 7, the distance measurement sensor800, replacing the laser 700, may be supported directly on one of thelaser modules 500 a, 500 b. With suitable software programminginstructions, the processing system 300 utilizes the distancemeasurement sensor 800 to locate external fixtures 600 or targets 602within the field of view. Proper placement of a fixture 600 or target602 relative to an established frame of reference, such as the vehicle(based on observations of wheel adapter targets) is determined by theprocessing system 300 in response to a measured distance to the fixture600 or target 602. The processing system 300 is configured to utilizegimbal encoder data for each associated rotational axis to identify aspatial orientation of the measurement axis for the measurement sensor800. If necessary, the processing system 300 can drive the motorizedgimbal 802 to orient the measurement axis of the measurement sensor 800towards an area in proximity to a vehicle or service bay, in which thefixture 600 or target 602 is expected to be placed.

In a further embodiment, use of a laser range finder or laserdisplacement sensor 800 functions as an additional means by which theprocessing system 300 can project a point of illumination onto surfaceswithin proximity to the fixture or support structure 100. Utilizing themotorized gimbal 802 to orient the measurement axis of the laserdisplacement sensor or laser range finder 800 towards a selectedlocation on a surface, the processing system 300 is configured toactivate the laser displacement sensor or laser range finder to emit alaser beam along the oriented measurement axis, illuminating theselected location.

In one embodiment, the processing system 300 is configured with softwareinstruction to utilize the measurement sensor 800 to determine if anexternal fixture 600 or target 602 has been properly positioned relativeto a location indicated by an optical projector 500 on the fixture orsupport structure 100. Once the optical projector 500 is oriented toilluminate a specific point or location for placement of the externalfixture 600 or target 602, an operator moves or places the externalfixture or target at the indicated location. Next, the processing system300 utilizes the measurement sensor 800 to measure a distance from thefixture or support structure 100 along an axis oriented towards thespecific point or location at which the external target 600 or fixture602 is expected. If the external fixture 600 or target 602 is properlypositioned, the processing system will receive an expected distancemeasurement from the measurement sensor 800. If the received distancemeasurement is outside of an acceptable tolerance of the expectedmeasurement, the processing system 300 is configured to provide theoperator with a warning or other suitable indication that the externaltarget or fixture 550 is not disposed at the expected location, and thatcorrective action may be required.

In a further variation, the processing system 300 may be configured withsoftware instructions to utilize the measurement sensor 800 to locate aproper location for place of an external fixture 600 or target 602relative to either the vehicle or to the support structure 100. Bycontrolling the motorized multi-axis gimbal 802, the processing system300 can acquire distance measurement data from the measurement sensor800 over an area or region in proximity to the vehicle or supportstructure 100. Once a location at a selected distance is identified fromthe measurement data, the processing system 300 utilizes an opticalprojector 500 and motorized multi-axis gimbal 502 to provide a visibleindication of the location to an operator, or simply activates theoptical projector 500 if the measurement sensor 800 is mounted on acommon multi-axis gimbal.

During a vehicle service procedure, the support structure 100 typicallyis disposed in front of the vehicle within the service bay. When placingan external fixture 600 or target 602 relative to either the vehicle orto the support structure 100 it may be necessary for a servicetechnician to move the support structure 100 out of the way to provideclearance at a placement location. If an external fixture 600 or target602 is to be placed in front of the vehicle in the service bay, such asfor service or inspection of a forward-looking ADAS system on thevehicle, it may be necessary to first identify the placement locationfor the external fixture or target using the optical projector 500, markthe location on the floor surface, and then move the support structure100 to provide a clear line of sight between the vehicle and theexternal fixture 600 or target 602 disposed at the marked location asseen in FIG. 9.

In a further embodiment, the processing system 300 is configured withsoftware instructions to eliminate the need for a service technician tomark the floor location prior to moving the support structure 100, andto enable the camera modules 104 a, 104 b to continue to acquire usefuldata after the support structure 100 is moved to a new location withinthe service bay relative to the vehicle 100. Initially, with the supportstructure located at a starting position at the front of the vehicle,the processing system 300 utilizes the camera modules 104 a, 104 b toacquire images of optical targets T mounted to the vehicle from which avehicle thrust line and a rear axle coordinate system (frame ofreference) are determined as is conventional with a machine-visionvehicle alignment or inspection system. Optionally, a fixed opticaltarget associated with a surface of the vehicle service area, such as awall, ceiling, or other stationary structure is observed as well.

Next, the support structure 100 is repositioned, as seen in FIG. 9, offto one side of the vehicle, while maintaining at least one of thevehicle-mounted optical targets T (or an optional fixed optical target)in a field of view of at least one of the camera modules 104 a, 104 b.Using the initially determined vehicle thrust line and rear axlecoordinate system data (or other established reference), the processingsystem 300 is configured with software instructions to determine the newposition of the support structure 100 relative to the vehicle using onlyimages of a single visible vehicle-mounted optical target T (or optionalfixed optical target). For example, the camera modules 104 a normallyviewing the front driver side of the vehicle may now acquire images ofan optical target T mounted to a rear wheel. So long as at least oneoptical target remains visible, the processing system 300 can acquiresufficient information from which to determine the relative positions ofthe vehicle and the support structure 100 in a common spatial referencesystem using well understood coordinate transform algorithms. With therelative positions known (or determinable), the processing system 300operates the set 502 of motorized gimbal mounting structures to orientone or both of the optical projectors 500 a, 500 b to project visibleindicia at the appropriate locations on the floor surface of the vehicleservice area for fixture 600 or target 602 placement, including floorsurface locations previously occupied or obstructed by the supportstructure 100, enabling an operator to carry out or complete a vehicleservice, calibration, or inspection procedure as noted above.

The relative position of the support structure 100 to the vehicle (orother fixed reference point) may alternatively be determined or trackedby utilizing a suitable movement tracking system, such as laser oroptical sensors (similar to computer mouse) located in the base supportstructure, or an inertial tracking system within the support structure100. A movement tracking system enables relative movement of the supportstructure 100 to be monitored when the vehicle wheel targets T or otherfixed reference point are not visible to the camera modules 104 a, 104b.

For many vehicle inspection, service, or alignment adjustmentprocedures, it is beneficial (or required) to have the vehicle disposedon a level surface. When placing external fixture 600 or targets 602 inproximity to the vehicle, it is assumed that the fixtures or targetswill be disposed on the same level surface as the vehicle. However, inmost vehicle service shops, the floor surfaces of the vehicle inspectionbays are not uniformly level. When a vehicle inspection, service, oralignment procedure requires that an external fixture 600 or target 602be disposed at a distance from the vehicle, errors or miscalculations inmeasurements may be introduced by uneven or un-level conditions in theservice bay floor.

Establishing a horizontal reference plane can aid in the placement ofexternal fixtures 600 or targets 602 facilitates the inspection,service, or alignment of a vehicle when floor conditions are less thanideal. In an embodiment of the present disclosure, a laser projectionsystem 850 disposed on the support structure 100, as seen in FIG. 4, isconfigured to establish a reference plane at a selected height relativeto the vehicle. The laser projection system 850 may consist of arotating laser or fan laser mounted to the support structure 100 ateither a fixed or vertically adjustable location and aligned to projectthe laser in a horizontal plane. Alternatively, one of the gimbalmounted laser emitters on an optical projector 500 a or 500 b may bedriven by the processing system 300 in a reciprocating or rotatingmovement about one axis of the gimbal structure to project a laser in ahorizontal plane. the placement of the optical projectors 500 a, 500 bon the support structure 100 establishes a reference plane at a knownvertical distance relative to the camera modules 104 a, 104 b. Onceplaced on the floor, the vertical height of the external fixtures 600 ortargets 602 can be adjusted relative to the established reference plane,rather than the uneven floor, such as by aligning index markings on thefixtures or targets with the rotating laser or fan laser illumination,or by guided adjustment in response to feedback provided by theprocessing system 300 based on observations of the fixtures 600 ortarget 602.

It will be further recognized that the establishment of a horizontalreference plane may be carried out prior to vehicle measurement orinspection, and utilized to characterize the contours of the floorsurface of the vehicle service bay during a set up or calibrationprocess. With the horizontal reference plane established, an externalfixture 600 or target 602 is moved about the vehicle service bay tovarious locations. At each location, the position of the fixture 600 ortarget 602 relative to the vertical height of the horizontal referenceplane is identified, effectively mapping a displacement between thefloor surface and the reference plane at each location. Granularity ofthe mapping is directly connected to the number of locations at whichthe fixture 600 or target 602 is positioned. Once the floor surface ischaracterized, during a vehicle service or inspection procedure,appropriate measurement offsets or corrective values can be applied tomeasurements acquired from the vehicle wheels, targets 602, or fixtures600 based on an associated location on the characterized floor surface.

The present disclosure can be embodied in-part in the form ofcomputer-implemented processes and apparatuses for practicing thoseprocesses. The present disclosure can also be embodied in-part in theform of computer program code containing instructions embodied intangible media, or another computer readable non-transitory storagemedium, wherein, when the computer program code is loaded into, andexecuted by, an electronic device such as a computer, micro-processor orlogic circuit, the device becomes an apparatus for practicing thepresent disclosure.

The present disclosure can also be embodied in-part in the form ofcomputer program code, for example, whether stored in a non-transitorystorage medium, loaded into and/or executed by a computer, ortransmitted over some transmission medium, wherein, when the computerprogram code is loaded into and executed by a computer, the computerbecomes an apparatus for practicing the present disclosure. Whenimplemented in a general-purpose microprocessor, the computer programcode segments configure the microprocessor to create specific logiccircuits.

As various changes could be made in the above constructions withoutdeparting from the scope of the disclosure, it is intended that allmatter contained in the above description or shown in the accompanyingdrawings shall be interpreted as illustrative and not in a limitingsense.

1. A method for guiding placement of a vehicle service external fixturerelative to a vehicle undergoing service or inspection, comprising:positioning a vehicle service system support structure having at leastone camera module at an initial location within a vehicle service area;establishing a location of said initial location within a vehiclereference frame using images of optical targets secured to the vehiclecaptured by a camera module disposed on said vehicle service systemsupport structure; repositioning the vehicle service system supportstructure relative to said vehicle to a new position, said new positionlocated outside of an external fixture placement region, whilemaintaining at least one of said observed optical targets within a fieldof view of said camera module; identifying said new position of saidvehicle service system support structure within said vehicle referenceframe from an image of said at least one optical target maintainedwithin said camera module field of vision; identifying, in said vehiclereference frame, a placement location relative to the vehicle for saidexternal fixture, said placement location within said external fixtureplacement region; and directing an operator to position said externalfixture at said identified placement location.
 2. The method of claim 1wherein identifying said placement location for said external fixtureincludes projecting visible indicia along an axis oriented to intersecta surface of said external fixture when said external fixture ispositioned at said identified placement location.
 3. The method of claim2 wherein said projected visible indicia presents either a line or aboundary for alignment of said external fixture at said identifiedplacement location.
 4. The method of claim 1 wherein identifying saidplacement location for said external fixture includes projecting visibleindicia along an axis oriented to intersect a floor surfacecorresponding to said identified placement location.
 5. The method ofclaim 1 wherein said external fixture placement region is located infront of said vehicle.
 6. A method for guiding placement of a vehicleservice external fixture relative to a vehicle undergoing service orinspection, comprising: positioning a vehicle service system supportstructure having at least one camera module at an initial locationwithin a vehicle service area; identifying said initial location withina vehicle reference frame using images of optical targets secured to thevehicle captured by a camera module disposed on said vehicle servicesystem support structure; determining, in said vehicle reference frame,a placement location relative to the vehicle for said external fixture;responsive to said determined placement location conflicting with saididentified initial location of said vehicle service system supportstructure within said vehicle reference frame, repositioning the vehicleservice system support structure relative to said vehicle to a newposition, said new position spaced from said determined placementlocation, while maintaining at least one of said observed opticaltargets within a field of view of said camera module; identifying saidnew position of said vehicle service system support structure withinsaid vehicle reference frame from an image of said at least one opticaltarget maintained within said camera module field of vision; anddirecting an operator to position said external fixture at saiddetermined placement location.
 7. The method of claim 6 whereindetermining said placement location for said external fixture includesprojecting visible indicia along an axis oriented to align with saidexternal fixture when said external fixture is positioned at saiddetermined placement location.
 8. The method of claim 7 wherein saidprojected visible indicia presents either a line or a boundary foralignment of said external fixture at said determined placementlocation.
 9. The method of claim 6 wherein determining said placementlocation for said external fixture includes projecting visible indiciaalong an axis oriented to intersect a floor surface corresponding tosaid determined placement location.